SPRINGBACK COMPENSATION PROCESS

Springback Compensation Process (SCP) is a module for calculation of springback compensation of tools. Application of advanced sheet materials such as aluminum alloy, high strength and ultra high strength steel helps to reduce body weight of an automobile without sacrificing the safety performance. Increasing application of advanced sheet materials to manufacture body of automobile has also created several issues in metal stamping industry. One of the crucial issues is the springback phenomenon as a result of elastic recovery of sheet material and uneven stress distribution after forming.

 

Traditionally, springback may be resolved in the shop floor by overcrown, overbend, restrike, stiffening darts, etc. Today, stamping CAE software plays a significant role in the prediction of springback of sheet metal components and compensation for tooling to alleviate springback. Using stamping CAE software, the user can conduct springback analysis and morphing of part after a sequence of process such as draw, trimming and flanging. However, springback compensation techniques are needed for users to compensate the original tooling surface to resolve the springback phenomenon. For decades, the springback compensation is performed depending on the experience of engineers. With advanced development of computer hardware and software technology, springback compensation can be quickly performed using CAE software such as eta/DYNAFORM.

 

In eta/DYNAFORM, springback compensation can be performed to correct part shape after springback to archive the dimension tolerance of intended part design. As illustrated in Figure 9.1, springback compensation is carried out after series of forming simulation and springback analysis. Iterative compensation approach may be adopted to obtain reasonable compensated tool surface.

 

 

Figure 9.1  Springback Compensation Procedure

SCP menu illustrated in Figure 9.2 provides functions such as COMPENSATION, RESULT CHECK, TOPOLOGY REPAIR, MORPHING, SURFACE MAPPING., BEST FIT and DEVIATION CHECK Detailed description of each function is given in the following sections.

Figure 9.2  SCP Menu